Jiaying Pan’s research while affiliated with Weichai Power and other places

To evaluate the significance of the geometrical parameters of a passive pre-chamber on engine performance, this study investigated the design of a plug-and-play passive pre-chamber in a 15 L heavy-duty natural gas engine. Multi-dimensional numerical investigations were conducted for parametric studies involving lateral angle, orifice diameter, and vertical angle. A compressive flow solver was employed for Navier–Stoke equations, coupled with detailed sub-models and a chemical kinetic scheme. The combustion model was calibrated and could well predict the engine combustion and operating performance. Seven pre-chamber schemes were evaluated, and four optimal ones were selected for experimental tests. The characteristics of the scavenging process, turbulent jet ignition, and main-chamber combustion were investigated and analyzed. The results show that, considering the trade-off between the ignition energy and the scavenging efficiency, the ratio of the pre-chamber to clearance volume is recommended to be 0.2~0.7%, and the corresponding area–volume ratio is 0.003~0.006 mm⁻¹. Compared with the original natural gas engine, the pre-chamber retrofit can save up to 13.2% of fuel consumption, which presents a significant improvement in fuel economy.

The pre-chamber technologies can improve the ignition performance of IC engines by more than two orders in magnitude and thereby substantial economic benefits. Compared with the common pre-chamber, a plug-and-play passive scheme is suitable for quick retrofit, which is getting more attention from the automobile industry. Good scavenging is the precondition for improving turbulent jet ignition performance for a passive pre-chamber. Therefore, detailed evaluations of the scavenging process and turbulent jet ignition deserve investigations for new pre-chamber schemes. In this paper, the effects of design parameters on ignition processes of plug-and-play passive pre-chamber were numerically studied, allowing for the lateral angle, orifice diameter, and vertical angle design. Seven pre-chamber schemes were evaluated, and four optimal ones were selected for bench tests. The characteristics of the scavenging process, turbulent jet ignition, and main-chamber combustion were investigated and analyzed. The results show that allowing for the trade-off between ignition energy and scavenging efficiency, the volume ratio of the pre-chamber to clearance is recommended to be 0.2~0.7%, and the corresponding area-volume ratio is 0.003~0.006 mm-1. Compared with the original natural gas engine, the pre-chamber retrofit can save up to 13.2% fuel consumption, which presents a significant improvement in fuel economy.

Nowadays, the carbon-free policies and the crisis of crude oil make natural gas get increasing attention. However, spark-ignited natural gas engines continually suffer from problems of thermal efficiency and NOx emissions. Optimizing intake and combustion systems are effective ways to improve combustion and emission performance, but comprehensive work involving both intake and combustion systems is still lacking, especially for heavy-duty commercial engines. In this work, both intake and combustion systems of spark-ignited heavy-duty natural gas engines were investigated using muti-dimensional numerical simulations. Two intake ports and four combustion chambers were considered. An optimized chemical model was employed to accelerate the computation efficiency of combustion processes. The optimal combination of intake and combustion systems was obtained, with impressive thermal efficiency and acceptable emission performance. The results show that the mixed-flow intake port performs better than the swirl intake port for the natural gas engine with premixed combustion mode, manifesting increased in-cylinder tumble ratio and turbulent kinetic energy. Meanwhile, the eccentric hemispherical combustion chamber (EHCC) combined with mixed-flow intake ports presents the best optimal combustion performance, exhibiting an effective thermal efficiency beyond 41.53%. However, the EHCC scheme shows an increased NOx emission due to fast combustion speed and high combustion temperature while negligible CO and CH4 emissions. Despite this, natural gas engines equipped with three-way catalysis after-treatment can still meet emission regulations under stoichiometric operating conditions.

Spark-ignited natural gas engines have received increasing attention in the heavy-duty market due to their low cost and reliability advantages. However, there are still some issues with natural gas engines retrofitted from 10 to 15 L diesel engines, which is a valuable medium-term goal for the automotive industry. In this work, the effect of intake port structure on the performance of a spark-ignited heavy-duty natural gas engine was investigated by multidimensional numerical simulations. A newly designed intake port was proposed, with strengthened in-cylinder turbulent kinetic energy and homogeneous air-fuel mixtures. Bench tests show that the proposed intake port has impressive thermal efficiency, cycle variation, and acceptable emissions performance. The effective thermal efficiency improves from 41.0% to 41.4%, and the cycle variation is 36% lower than traditional schemes. However, with the accelerated flame propagation, the in-cylinder temperature and NOx emission of the mixed-flow port increase while the CO emission decreases. In summary, a proper balance of in-cylinder swirl and tumble flow can significantly affect the economy and stability of natural gas engines. The proposed structure solves the inherent problems of slow natural gas flame propagation and harmful cyclic variations.

As a carbon-free hydrogen-carrier fuel with a high content of hydrogen, ammonia (NH3) exhibits unfavorable combustion properties such as low flammability and large cyclic variations, requiring further investigation in actual engines. In this work, for the first time, using a single-cylinder optical spark ignition (SI) engine with a high compression ratio, engine performance as well as combustion and flame propagation characteristics were investigated. Synchronization measurement of in-cylinder pressure and high-speed photography was performed, and the combustion characteristics were compared between ammonia and methane under the same operating conditions. The results show that the combustion stability and power capability of ammonia are significantly lower than that of methane. Further analysis combining combustion phasing and flame propagation characteristics indicates that the burning time loss mainly comes from the initial flame development process rather than the main combustion duration which results in a deficit in engine performance. The average probability maps of the flame location indicate that the flame front propagation of the two fuels emerges with obviously different characteristics. Quantitative flame solving shows that NH3 flame propagation features a higher flame stretch sensitivity which is macroscopically reflected in the cyclic variations. Furthermore, the quantification of flame response to turbulence was solved and observed much higher effects for NH3 flame than methane, which indicates NH3 flame propagation is mainly driven by the flame response to turbulence while the flame propagation of methane exhibits higher sensitivity to temperature than ammonia. The current study shall provide insights into the application of ammonia in the internal combustion engine.

Improving thermal efficiency and reducing carbon emissions are the permanent themes for internal combustion (IC) engines. In the past decades, various advanced strategies have been proposed to achieve higher efficiency and cleaner combustion with the increasingly stringent fuel economy and emission regulations. This article reviews the recent progress in the improvement of thermal efficiency of IC engines and provides a comprehensive summary of the latest research on thermal efficiency from aspects of thermodynamic cycles, gas exchange systems, advanced combustion strategies, and thermal and energy management. Meanwhile, the remaining challenges in different modules are also discussed. It shows that with the development of advanced technologies, it is highly positive to achieve 55% and even over 60% in effective thermal efficiency for IC engines. However, different technologies such as hybrid thermal cycles, variable intake systems, extreme condition combustion (manifesting low temperature, high pressure, and lean burning), and effective thermal and energy management are suggested to be closely integrated into the whole powertrains with highly developed electrification and intelligence.